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1 Conveyorppt Course 2010
1 Conveyorppt Course 2010
K. Pathak
mobile slope conveyor at Kazagistan with a capacity of 5500 m/h and capacity to handle height differences up to 28 m.
Apron Feeder
Middlings
Components
DISCHARGE HOOD
TRIPPER
IMPACT IDLERS
BEND PULLEY SNUB PULLEY CARRYING IDLERS RETURN IDLERS BELT CLEANER
GRAVITY TAKE-UP
Level or inclined Conveyor receiving material at tail end and discharging at head en
Level Conveyor receiving material at any point through travelling Hopper and discharging at head end.
Level and inclined Conveyor receiving material at and near tail end, having vertical curve to incline, and discharging at head end.
Level and inclined Conveyor with chute. Material received from bins too close to elevated head end to permit use of vertical curve.
Inclined and level Conveyor receiving material at tail end and discharging from level section through a movable Tripper.
Level Conveyor on raised structure with double-wing Tripper forming storage piles on both sides of Conveyor.
Inclined Conveyor receiving material at tail end and discharging at several points through a series of fixed Trippers.
Many other functions can be performed with the basic conveying like weighing, sorting, picking, sampling, blending, spraying, cooling, drying etc. Structurally it is one of the lightest forms of conveying machine. It is comparatively cheaper and supporting structures can be used for many otherwise impossible structures such as crossing rivers, streets and valleys. The belt conveyor can be adopted for special purposes (fire resistant, wear resistant, corrosion resistant, high angle negotiation etc.) and can be integrated with other equipment. It can be horizontal, incline or decline or combination of all. Minimum labor is required for the operation and maintenance of belt conveyor system. In underground mine transport, belt conveyor can be used in thin seams as it eliminates the rock works that might otherwise be required to gain haulage height. Moreover, belt conveyor can provide continuous haulage service from pit bottom to the surface.
Limitations
The loading and transfer points need to be properly designed. Numbers of protective devices have to be incorporated to save the belt from getting damaged by operational problems. The belt needs higher initial tension (40-200% of useful pull).
The use of belt is restricted by the lump size. If the maximum diagonal of a irregular lump is X then the belt width (B) is approximately given by: B>=Xa+200 Where, B: Belt width, mm X: Longest diagonal of irregular lump, mm a: Factor to account for grading. a is taken as 2.5 for graded material and 3 for ungraded material. However, for particular material these values must be properly estimated. Conveying of sticky material is associated with problems of cleaning and discharge causing poor productivity. Higher elongation of the belt (4% elongation may take place at the working load).
Portable: These are characterised by relative ease of assembling and disassembling to facilitate advances and recovery in development and retreat operations in underground mining.
Shiftable: Used in continuous surface mining this type of conveyor is mounted on skid or supporting structures aligned together and the whole can be shifted transversely to follow the advancing working face.
High Angle Conveyor: These are special type of conveyor belt arrangement used for negotiating steeper angle of inclination. Such belts can work in slope up to 70-800. Sandwich belt conveyor is a type of such belt conveyor.
Cable Belt Conveyor: Where the belt is carried on moving wire ropes and the tractive force is applied through the rope to the belt is known as cable belt conveyor..
Pipe Belt Conveyor: The belt is made to form a pipe while running the main length of the conveyor. At the receiving and discharge end the belt is like troughed belt conveyor. They are suitable for having spillage free transportation and free from risk of polluting the environment.
Cont
Mobile Transfer Conveyor: Mobile Transfer Conveyors are installed between Bucket Wheel/Chain Excavators and the shiftable bench conveyor allowing multi block and multi bench operations to increase the block width and the block height. Thus, increasing the time between two shifting operations of the bench conveyor results in a higher utilization of the mining system. Grasshopper style Mobile Transfer Conveyors: Installed as a chain like one connected to the other are part of waste dumping. This can eliminate dump trucks from mines. Mobile transfer conveyor
End Cover
End Cover
Flexibility Transverse rigidity Low mass per unit length High strength Simplicity and inexpensive Longer life Should not stretch under normal working stresses ,i.e., low relative elongation. Wear resistant Fire resistant
Top C over
Bottom Cover
Rubber Interply
Belt Fastener
BELT SCRAPERS
V- Plow
Diagonal Plow
Self-adjusting unit eliminates the need to readjust to accommodate blade wear. Stainless steel turnbuckle permits precise adjustment so the plow can be fine-tuned to the belt at installation and eliminate unit vibration. Can also be positioned directly behind the head pulley to dump debris at the transfer point.
The diagonal deflector plow is installed on a 45 angle across the belt to discharge debris to one side of the belt. In such cleaners the blade is installed in a fixed position, eliminating bouncing problems associated with some floating style plows.
Twin-bladed plow is designed to clean belt in both directions of travel. This cleaner discharges material to either side of the belt. It is installed securely to conveyor structure and can work on conveyors with severe belt vibration.
Idlers
Self aligning idler set is used infront of the loading point. This set of idlers can rotate on a horizontal plan depending on the belt sway and restores true running of the belt. Belt training idlers should be spaced 30 to 50 m apart and at least one such idlers should be used on conveyors less than 30m long. Such idlers are not used in the areas of belt transition.
Idler spacing
Belt Width (inches) Troughed Idler Spacing Weigh of Material Handled (lbs/cu ft) 30 50 75 100 150 200 Return Idler
18 24 30
36 42 48 54 60 72 84 96
Pulley
A conveyor belt system uses different types of pulleys like end pulley, snub pulley, bend pulley
Belt trainer
PT Smart trainer can be installed at the head pulley or tail pulley, before or after the take-up, or virtually anywhere mistracking occurs along the return belt.
Belt Cutter
The carrying side needs cleaning when carried material is sticky in nature. belt cleaner that uses a belt with anti-stick coating and claims minimization of downtime for cleaning.
The performance of belt cleaner depends on: Constant tension between the cleaner and the conveyor belt. Condition of the conveyor belt. Type of material sticking to the belt.
200
350
450
Loose Snub
Tight Snub
Drive Arrangement
Tensioning Arrangement
The purposes of take-up are: To allow for stretch and shrinkage of the belt. To ensure that the minimum tension in the belt is sufficient to prevent undue sag between idlers. To ensure that the tension in the belt in the rear of the drive pulley is sufficient to permit such pulley to transmit the load.
Types
1. 2. 3. Screw Take-up Loop Take-up Gravity Take-up
Screw take-up
Gravity Take up
Belt Protection Controls: devices provided for protecting conveyor belt system
Belt Overload: The electric drive motor has overload protection. The motor overload can be a simple bi-metallic or melting eutectic alloy or a complex computer based motor-thermal model. Sometimes belt weigh scales are also used for overload protection. Belt Slip: Belt slip is the loss in traction of the drive pulley(s) to the belt cover. Belt slip can destroy a belt or drive pulley. Belt slip protection provides a belt drive speed sensor that compares the present belt speed with the belt intended speed. For constant speed belts belt slip monitoring is done by a slip switch with a setpoint that trips the conveyor drive when the belt speed is below 80% of full speed. The belt slip switch is bypassed during starting and stopping. For variable speed conveyor belt slip monitoring consists of a speed sensor that measures the belt speed and compares with the speed reference sent to the drive system. When the belt speed is below 80% of the intended speed the conveyor drive is tripped. A method to adjust and test belt slip is normally provided in the belt control system.
Take-up Overtravel : Overtravel limit switches can be placed at the far extremes of the counterweight or take up device travel. In a gravity counterweight take-up, the top overtravel switch trip may suggest a jammed conveyor belt condition. A bottom overtravel switch may indicate belt stretch, or a broken belt fabric flight. Excessive take-up motion during starting and stopping indicate that the type of drive control is either inadequate or that is not working properly.
Fire Detection: Thermal trip switches are provided with smoke sensors, CO sensors or fibre optic temperature sensors. Dust Sprays: Water or chemical based dust suppressing system can eliminate or reduce dust problems in certain special conveyor belt installations
Complaint
Complaint of
Excessive wear
bottom cover
wear,
15, 22, 21, 16 19, 7, 21, 14, 22 19, 7, 22, 10 13, 10, 21, 6, 9 2, 23, 13, 22, 20, 10
Covers become checked or brittle Longitudinal grooving or cracking of top cover Longitudinal grooving or cracking of bottom cover Fabric decay, carcass cracks, ruptures, soft spots in belt(gouges) Ply separation
1.Belt bowed: Avoid telescoping belt rolls or storing them in damp locations. 2.Belt improperly spliced or wrong fasteners: Use correct fasteners. Retighten after running for a short while. If temporarily spliced remove belt splice and make new splice. Set up regular inspetion schedule. 3.Belt speed too fast: Reduce belt speed 4.Belt strained on one side: Allow time for new belt to break in. If belt does not break in properly or is not new, remove strained section and splice in a new piece. 5.Breaker strip missing or inadequate: When service is lost, install proper breaker strip ( Breakers are woven fabric of nylon &/or polyster placed above the carcass to dissipate impact energy and to prevent belt puncture) 6.Counterweight too heavy: Recalculate weight required and adjust counterweight accordingly. Reduce take-up tension to point of slip then lighten slightly. 7.Counterweight too light: Recalculate and adjust or screw take-up accordingly. 8.Damage by abrasive, acid, chemicals, heat etc: Use belt designed for specific purpose. Repair cuts. Use enclosure where needed.
9.
10. Drive underbelted: Recalculate maximum belt tensions and select correcxt belt. Determine if extension is feasible or another belt to be installed. Check the carcass is rigid enough for load, replace if service is lost. 11. Edge worn or broken: Repair edge. If the edge is out of square or badly damage replace the worn portion of the belt. 12. Excessive impact of material on belt or fasteners: Use correctly designed chutes and baffles. Make vulcanised splices. Instal impact idlers. Where possible load fines first. Where material is trapped under skirts , adjust skirtboards to minimum clearance or install cushioning idlers to hold belt against skirts. 13. Excessive tension: Recalculate and adjust tension. Use vulcanised splice within recommended limits. 14. Frozen Idlers: Free idlers. Lubricate. Improve maintenance. Dont over lubricate.
15. Idlers or pulleys out of square with centre line of the conveyor: Realign. Install limit switches for greater safety.
16. Idlers improperly placed: Relocate idlers or insert insert additional idlers spaced to support belts.
17. Improper loading, spillage: Feed should be in direction of belt travel and at belt speed, centred on the belt. Control flow with feeders, chutes and skirtboard.
18. Improper storage or handling: Refer to the manufacturers instructions for storage and handling.
19. Insufficient traction between belt and pulley: Increase wrap angle with snub pulley. Lag drive pulley. In wet condition use grooved lagging. Install correct cleaning devices for safety. 20. Material between belt and pulley: Use skirtboard properly. Remove accumulation. Maintain properly. 21. Material build-up: Remove accumulation. Install cleaning devices, scrapers and inverted V decking. Improve housekeeping. 22. Pulley lagging worn: Replace worn pulley lagging. Use grooved lagging for wet conditions. Tighten loose and protruding bolts. 23. Pulleys too small: Use large diameter pulleys.
24. Radius of convex vertical curve too small: Increase radius by vertical realignment of idlers to reduce excessive edge tension.
25. Relative loading velocity too high or too low: Adjust chute or correct belt velocities. Use impact idlers. 26. Side loading: Load in the direction of belt run and at the centre of the belt.
27. Skirts improperly Placed: Use adjustable skirtboards and check that it does not rub the belt.